HEAT INTEGRATION Analysis 6.

Data extraction

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06. Data extraction 1

Outline
Data extraction Required data Rules and guides (1 to 5) Process modification Plus/minus principle

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06. Data extraction 2

Data extraction
To pull out data from the PFD and include it into the problem General principles:
it's about disconnecting the existing solution (in order to reconnect it) to extract only requirements don't extract mandatory features: leave it as they are extract heat (and cold) that can actually be used by other streams

Poor data extraction can lead to two extremes:

thinking that process is at its optimum (if maintaining excessive features) over-estimating the room for improvement (if extracting too much)

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06. Data extraction 3

Required information/data
As a minimum: Problem Table
Supply and target temperatures Stream heating and cooling data: enthalpies and/or mCps

Information on existing/planned utility system Information on costs:

Energy (utilities) Equipment
Heat exchangers material, pressures, type... Utility system devices

General and background information on the process

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06. Data extraction 4

Rules - Guides (1)

Doesn't extract / doesn't include in the problem:
Mandatory parts / parts that cant' be changed
e.g.: Using quenching steam generation in a reactor This heat cannot be used in other way

True utility streams

(utility that can be replaced by other) Quenching (steam generation) Cold shots for reactor hot spots control Steam in a shift reactor (to enhance the shift process) Steam injection for steam distillation (different from direct steam to reboil the column - only heat transfer)

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Rules - Guides (2)

Doesn't extract / include in the problem:
Linked or chained Energy flows
Reaction (most cases) Compression / expansion H can't be integrated

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06. Data extraction 6

Rules - Guides (3)

Don't maintain unnecessary / too detailed features
Extend (conceptual) streams as much as possible (energy streams are not material streams)

NO
T1 T2 dH ------------------35.0 45.5 +191 120.0 55.0 -191 45.5 91.5 +832 210.0 65.5 -832 91.5 130.0 +697 -------------------

YES
T1 T2 dH ------------------35.0 130.0 +1720 120.0 55.0 -191 210.0 65.5 -832 -------------------

Long no-linear streams can be linearized by segments for calculation purposes, but conceptual stream is one. Linearization is just a calculation trick Correct, if possible up-down-up temperatures (heating-cooling-heating)
T1 T2 dH -------------------35.0 150.0 +80 150.0 180.0 +20.9 180.0 130.0 -34.8 -------------------T1 T2 dH ------------------35.0 130.0 +66.1 -------------------

NO
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YES
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Rules - Guides (4)

Look at hidden (direct) heat exchange
Mixing streams Injecting streams (e.g.: process water) Heating/cooling opportunities are lost

Heat exchange is been condemned to this configuration (no mandatory) Can involve heat transfer across the pinch Calculating targets with/without mixing assess extraction or not

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06. Data extraction 8

Mixing calculation (1)

[Approximations: constant mCp, no mixing effects, no phase change] From mCp :
mC P1 T 3 T 1 = mC P2 T 3 T 2 mC P1 T 1 mC P2 T 2 T3 = = 428,6 K mC P1mC P2 Duty 1 = mC P1 T 3 T 1 = 10286 kW Duty 2 = mC P2 T 3 T 2 = 10286 kW

kW K Duty 2 = mC P2 T 3 T 2 = 12000 kW = Duty 1 Duty1 T 1 = T3 = 316.7 K mC P1 Duty 1 = mC P1 T 3 T 1 = 12000 kW mC P1 = mC P3 mC P2 = 90

Valid for absolute or relative (C or F) temperature

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Mixing calculation (2)

[Approximations: constant mCp, no mixing effects, no phase change] From enthalpies:

kJ kJ , H 2, rel = 0 kg kg H 1, rel 1400 kJ / kg kJ C P1 = = = 4.667 T 1 T 2 300 K kg K kg kJ kW mC P1 = m 4.667 = 4.667 1C P1 = 1 s kg K K kW Duty 1 = mC P1 T 3 T 1 = 4.667 400 K 600 K = 933.3 kW K Duty 2 = Duty 1 = 933.3 kW T REF = T 2 H 1, rel = H 1 H 2 = 1400

Just a rough approximation

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Rules - Guides (5)

Extract/approximate non-linear streams the safe side

SAFE DANGEROUS DANGEROUS

SAFE

Hot streams hotter / Cold streams colder than approximations

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Process modification
Changing the material and energy balances to reduce requirements in utility / equipment Hard and soft / flexible and rigid constraints.
P/T vaporization/condensation T of streams to storage Column reboiler/condenser P/T

Process modification possibilities

Distillation column operating pressure Feed vaporization pressure Pump-around flow rates Reactor conversion / recycle

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Plus-minus principle 1
Identify/characterize changes in PFD (operation conditions) that improve energy performance

Good modifications:
Those that decreases hot utility:
Increasing hot stream duty above the pinch Decreasing cold stream duty above the pinch

Those that decreases cold utility:

Decreasing hot stream duty below the pinch Increasing cold stream duty bellow the pinch

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06. Data extraction 13

Plus-minus principle 2
Also changing Ts
Changes of T confined to one side of the pinch have no effects on energy targets Changes of T across the pinch can have effects on energy targets (if shift duty across to) Shift hot stream duty from below to above the pinch / Shift cold stream duty from below to below the pinch As a general rule: made hot streams hotter and cold streams colder
Can shift duty the right way Widen T between curves/improve driving forces

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06. Data extraction 14